Royal Enfield Interceptor 650 - Service manual > Piston RH in Cylinder Barrel

• Ensure cylinder barrel RH is well lubricated, RH piston is at its top most position, held firmly and straight.
• Locate special tool over piston RH.

• Gently lower cylinder barrel (a) till piston RH is halfway into the cylinder barrel.

• Hold cylinder barrel firmly in suspended position and remove the special tool (a) from piston RH.

• Gently lower cylinder barrel further, till it is firmly seated on the crankcase.
• Locate 2 Nos. dowel pins (a) on cylinder barrel and ensure they are seated properly.

Cylinder Head Gasket on Cylinder Barrel

• Ensure the gasket seating surface on cylinder barrel is clean.
• Ensure4 cam chain is routed through a new cylinder head gasket.
• Locate new head gasket (a) on cylinder barrel and ensure it is properly seated on the dowel pins and cylinder barrel.

Floating Chain Pad

• Hold timing chain (a) suitably and insert chain pad (b) into cylinder barrel with the chain contact area facing inside.

CAUTION Ensure floating chain pad seating correctly in the crankcase and free radial movement.

Components in Cylinder Head

Components in Cylinder Head

Valves and Springs

• Install 8 Nos. valve stem seals (b) on the 8 Nos. valve guides (a).

• Lubricate and insert the valves (a) into the valve guides inside cylinder head (b).

• Support the valve inside cylinder head and assemble valve spring (a) over valve stem (b) in the outer area of the cylinder head.

• Insert collar (a) above valve spring (b).

• Locate special tool on the valve such that the threaded screw end of the tool is seated centrally on the valve inside the cylinder head and the other end is seated on the valve spring collar on the outer side of the cylinder head.
• Compress valve spring with special tool (a) by "hand tightening" the threaded screw of the special tool gently, till it locks against the valve.

CAUTION Do not overtighten the special tool as it will damage both the valve seating surface and the special tool.

• Locate two split cotters (a) on the collar with their tapered end facing inside and the flat edges seated against the valve stem top portion.

• Gently and slowly release special tool by unscrewing the threaded shaft, duly ensuring the valve cotters are locked in place on the valve stem and the tapered surfaces of the cotters are inside the valve spring collar.
• Remove special tool (a) from the valve.

• Repeat the above process to install the other seven valves, springs, collars and cotters on the cylinder head.

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